Electrochemical actuators and actuator arrays

Abstract

Electrochemical actuators including a sealed electrolytic chamber with two or more electrodes disposed therein and associated reservoirs are described. In some embodiments, the electrochemical actuators include one or more rigid structures that are overmolded onto one or more electrodes to form the electrolytic chambers. In some embodiments, multiple rigid structures that are overmolded onto two or separate electrodes may be connected to form one or more electrolytic chambers with a desired configuration of electrodes contained therein. Manufacturing methods and structures related to the formation of an array of electrochemical actuators are also described.

1 - 47 . (canceled) 
     
     
         48 . An actuator comprising:
 a sealed electrolytic chamber, wherein the sealed electrolytic chamber includes a first rigid portion and a compliant portion at least partially enclosing an interior of the sealed electrolytic chamber; and   a first electrode extending from an exterior of the sealed chamber to an interior of the sealed chamber through the first rigid portion.   
     
     
         49 . The actuator of  claim 48 , further comprising a second rigid portion of the sealed electrolytic chamber and a second electrode extending from the exterior of the sealed electrolytic chamber to the interior of the sealed electrolytic chamber through the second rigid portion, wherein the first rigid portion is bonded to the second rigid portion of the sealed electrolytic chamber. 
     
     
         50 . The actuator of  claim 48 , further comprising a second electrode extending from the exterior of the sealed electrolytic chamber to the interior of the sealed electrolytic chamber through the first rigid portion. 
     
     
         51 . The actuator of  claim 50 , wherein the first and second electrodes are interdigitated. 
     
     
         52 . The actuator of  claim 48 , further comprising:
 a reservoir configured to contain a liquid attached to the sealed electrolytic chamber, wherein the compliant portion of the sealed electrolytic chamber forms at least a portion of the reservoir such that deformation of the compliant portion into an interior of the reservoir displaces the liquid out of the reservoir.   
     
     
         53 . The actuator of  claim 48 , wherein the compliant portion comprises a first membrane. 
     
     
         54 . The actuator of  claim 53 , further comprising a second layer attached to the sealed electrolytic chamber such that a volume disposed between the first membrane and the second layer forms a reservoir configured to contain a liquid. 
     
     
         55 . The actuator of  claim 54 , wherein the second layer is a second membrane. 
     
     
         56 . The actuator of  claim 48 , further comprising:
 a fluid tight seal between the first electrode and the first rigid portion of the sealed electrolytic chamber.   
     
     
         57 . The actuator of  claim 48 , further comprising:
 a through hole extending from an exterior surface of the first rigid portion to an interior surface of the first rigid portion.   
     
     
         58 . The actuator of  claim 57 , further comprising a seal disposed on, or in, the through hole. 
     
     
         59 . The actuator of  claim 48 , further comprising an electrolyte disposed in the sealed electrolytic chamber that decomposes to generate a gas when exposed to a predetermined voltage potential and/or current. 
     
     
         60 . The actuator of  claim 48 , wherein the compliant portion is configured to extend at least partially into an interior of the chamber in an initial configuration. 
     
     
         61 . The actuator of  claim 48 , wherein the sealed electrolytic chamber is overmolded onto at least a portion of the first electrode. 
     
     
         62 . The actuator of  claim 48 , wherein the first rigid portion of the sealed electrolytic chamber is overmolded onto a portion of a second electrode, wherein the second electrode is exposed to the interior of the sealed electrolytic chamber. 
     
     
         63 . An actuator array comprising:
 a plurality of sealed electrolytic chambers formed in a rigid structure, wherein each sealed electrolytic chamber of the plurality of sealed electrolytic chambers comprises:   an opening; and   at least two electrodes extending from an exterior of the sealed electrolytic chamber to an interior of the sealed electrolytic chamber; and a first membrane disposed on the plurality of sealed electrolytic chambers, wherein the first membrane seals the opening of each sealed electrolytic chamber.   
     
     
         64 . The actuator array of  claim 63 , wherein the first membrane is configured to extend at least partially into an interior of each sealed electrolytic chamber in an initial configuration. 
     
     
         65 . The actuator array of  claim 63 , further comprising:
 a second layer disposed on the first membrane wherein the second layer is bonded to the first membrane and/or the plurality of sealed electrolytic chambers around a periphery of each opening of the plurality of sealed electrolytic chambers to form a plurality of reservoirs disposed between the first membrane and the second layer.   
     
     
         66 . The actuator array of  claim 65 , further comprising:
 a third layer disposed on and bonded to the second layer to form a plurality of reservoirs between the second and third layers associated with the plurality of sealed electrolytic chambers such that actuation of the sealed electrolytic chambers deforms the first membrane against the second layer to displace fluid from within the associated reservoirs.   
     
     
         67 . The actuator array of  claim 65 , further comprising a plurality of channels formed between the first membrane and the second layer fluidly connected to the plurality of sealed electrolytic chambers.